The investigation of the splashing and spreading behaviour of an impacting powder particle during the plasma spraying process is a field of research often performed with the help of simulations. To simulate thermal sprayed coatings at large scale, the Monte Carlo method is a useful technology. In the Monte Carlo model presented in this manuscript, spreading starts from the particle impact point and continues over the coating so that the behaviour at steps or other surface structures can be taken into account. The discretisation of the model is only lateral so that the thickness of the coating perpendicular to the substrate can take arbitrary values. The rules for particle spreading and deposition used in the Monte Carlo model are derived from a fluid dynamics model. For a two-dimensional simulation the Monte Carlo results provides good agreement with the fluid dynamics results.

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